Project Background
A leading construction equipment manufacturer approached XinSheng to develop an integrated cooling solution for their new medium excavator platform (30T class). The existing design used separate radiator, charge air cooler, and hydraulic oil cooler components, creating assembly complexity and serviceability challenges.
Customer Requirements
- Thermal Performance: Combined heat rejection of 120 kW (engine coolant 70 kW, charge air 25 kW, hydraulic oil 25 kW)
- Operating Environment: Ambient temperatures up to +50°C, extreme dust conditions, high altitude operation
- Vibration Rating: Track-induced vibration per customer duty cycle specification
- Packaging Constraint: 15% reduction in overall package volume vs. existing solution
- Serviceability: Easy-clean design for field maintenance in dusty environments
Engineering Approach
Phase 1: System Analysis
Our application engineering team conducted thermal and mechanical analysis of the existing system. CFD simulation identified airflow restrictions in the original multi-component layout that limited cooling capacity under low-speed operating conditions.
Phase 2: Integrated Design
We developed a 3-in-1 modular cooling pack integrating all three heat exchangers into a single frame assembly:
- Staged core arrangement optimized for differential temperature requirements
- Common tank design reduced weight and eliminated inter-cooler connections
- Reinforced mounting provisions addressed vibration concerns
Phase 3: Validation
The prototype underwent comprehensive testing in our laboratory:
- Thermal performance verified on wind tunnel
- Vibration fatigue testing to customer specification
- Pressure cycling and leak testing per IATF requirements
Key Success Factors
- Early Engagement: Involvement from concept phase allowed optimization of package layout
- Integrated Testing: In-house thermal and vibration testing accelerated validation
- DFM Focus: Design for manufacturing reduced production complexity
- Serviceability: Wide fin spacing (4 FPI) and hinged mounting enabled field cleaning
Production Status
The integrated cooling module entered volume production in Q4 2024 and is now installed in excavators operating across Asia and Europe.
Note: Specific customer details and proprietary specifications are confidential. Contact our engineering team to discuss similar applications.
